Introduction
Dalal Engineering, a pioneer in High Temperature, High Pressure dyeing technology (HTHP Dyeing machine) in India, was set up over 69 years ago. In 1966, we collaborated with M/s Obermaier & Cie of Germany who were pioneers in HTHP dyeing machines, and have steadily grown into a universally acknowledged manufacturer in the sphere of package dyeing machines. We have maintained our position of market leader, by constantly updating our technology through continuous research and development.We have successfully installed over 1600 dyeing machines all over the country and even abroad. Be it 100 Gms or 3000 Kgs, we have the expertise to manufacture the dyeing machines to match customer's specific requirements. Our states-of-the art manufacturing plant is strategically located, on the outskirts of Mumbai, having latest equipment for manufacturing and testing the dyeing machines.
Our current range of machines are now more eco-friendly, with features like Air Pad system for reduced water, steam, power and dyes / chemicals consumption. Variable Frequency Drive is provided for greater energy efficiency. The MLR is as low as 1:3 to 1:5 depending upon substrate and process.
Today the dyers expects 'First Time Right' results from package dyeing machines to meet shorter delivery schedule at lowest operating cost. To achieve repeatability of shades in production, the main liquor-circulating pump plays a very important role. Dye Liquor is required to be circulated for making maximum number of contacts without damaging the textile substrate and Pump should have characteristics which achieve just-right liquor flow through the package. Our Turbo pump achieves this result effortlessly.
Salient Features
Air Pad System:
This feature makes it a most cost effective & environmentally friendly application. Its advantages are:
- Reduced water quantity to bring down steam, electricity and chemical requirements.
- Uniform temperature in kier volume and excellent exhaustion of dyestuff
- In vat dyeing of cotton, the dye liquor is not subject to continuous oxidation by external air
- Reduced air pollution as dissolved chemicals do not escape to air
 Variable Frequency Drive:
Inverter controlled turbo pump motor helps achieve automatic step less speed control in both directions of flow. VFD reduces power consumption during start up, flow reversal and partial load dyeing.
Adjustable Liquor Ratios:
Best liquor ratio can be selected depending on various process parameters with Analog Level Controller for complete dyeing process
- Low liquor ratio during dyeing
- Minimum MLR can be selected for Full Load or Partial Load dyeing phase
- Ultra-low liquor ratio can be selected, whenever possible, for dyeing and subsequent washing cycles
Safety and Interlock Systems:
The main lid of the machine is in 3-piece OSV type lid, operating with a pneumatic lifting and lowering cylinder and all required safety locks such that it cannot be opened unless the machine is fully depressurized and temperature is below 80° C.
- Auto pressure control valve set at 4 kg/cm2. Releases built-up pressure
- Mechanical pressure safety valve set at 4.5 kg/cm2
- Main pump protection to safeguard against dry run
- Interlocking of “Heating On” and main pump motor
Automation
Dalal Package Dyeing Machines have an imported micro controller and PLC. They can also be linked to a central host computer station for dye-house management. The machines have an industrial PC with graphic touch screen interface. Some of the automated functions are:- Filling – several types of water to a number of levels.
- Filling to a programmed quantity.
- Ratio fill – allowing quantity filling in relation to the material weight.
- Filling with analog level sensor to any programmed percentage.
- Flow reversal programme – allowing the selection of the duration of flow in each direction.
- Circulation pump speed setting.
- Pulsating flow during liquor circulation.
- Machine pressurisation/ depressurisation.
- Controlling the rate of heating & cooling, final temperatures and holding time.
- Signals for preparation and control of the transferring of the contents of a side chemicals tank, followed by automatic rinsing.
- Programmed Dosing.
- Parallel preparation of Stock Tank, including: filling, heating, signal for addition of dyes/chemicals and transferring to the main dyeing vessel.
- Combined rinsing and cooling.
- Draining facility for Normal drain, High Temperature drain and Pressure drain.
- Signals for operator intervention, including: load, unload, sample, check, etc.
- Automatic fault finding system.
- Function overrides with manual intervention within controller
- Switches to operate machine in manual mode.
Additional Features
Pressure Extraction:
The machine is pressurized by compressed air to remove excess heavily coloured water reducing water consumption and rinsing time. The process is repeated at the end of the dye cycle to remove excess water making handling of the carrier easy and keeping the area of operation clean.Differential Pressure Controller:
Continuously monitors differential pressure of packages and automatically adjusts pump speed to achieve pre-set values reducing power consumption considerably.
Shock Rinse:
Reduces fresh water consumption due to efficient washing and improves rubbing fastness. Selection of this application however, depends on the class of dyestuffs and its suitability for such a treatment.Dye Kitchen Equipment:
Automated dye-kitchen equipment interfaced with microprocessor of main machine also available.Operating System:
Air pad is the standard production machine. However, for specific needs we can manufacture machines having Fully Flooded or Dual mode system.Heating System:
Apart from steam as heating media, we can also deliver machines suitable for Hot Oil or Pressurized Hot Water system.Coupling:
Coupling of two or more machines of identical capacity with automation can be supplied for dyeing larger capacity lots.Material Carriers
Interchangeable Material Carriers of a wide range for substrates in different forms are available with Dalal. For tall machines, specially designed double decker carriers and warp beam carriers are also available.
Cheese Carrier
Cheese carriers feature spindles that are tailor-made to suit various types of dye centers and package dimensions. Cheese carriers supplied with self lowering locking devices.
Variable Load Cheese Carrier
Suitable for dyeing reduced batch sizes up to 50% of the rated capacity.
Fibre / Muff Carrier
Packing Cylinders suitable for dyeing loose stock and muffs are robustly designed. They are supplied with lifting plates for easy unloading of material. Heavy duty packing cylinders are designed for hydraulic pressing. Special types can go into a centrifugal hydro extractor along with the material.
Top Carrier
These carriers are designed for easy loading and unloading of tops and are constructed specially to ensure years of trouble free service. Gravity lowering caps help to take care of shrinkage during the process.
Unloading Basket
Recommended for large dia/ higher capacity machines. Helps reduces time taken to unload the yarn packages from cheese carrier. Most importantly it reduces man power required.
Zipper Tape Carrier
Suitable to receive various sizes of spools (bobbins)
Locking Devices
Various types of locking devices and plates are supplied to suit individual requirements of different packages.
Presses
Pneumatic Press
To press down dye-spring packages on to the cheese carrier spindles including movable turntable trolley.
Hydraulic Press
To press down loose stock and helenca muffs into packing cylinder with suitable adopters and movable turntable trolley.
Laboratory Dyeing Machine / Sample Dyeing Machine
Dyeing Machine
Dalal Engineering’s laboratory dyeing machines are for sampling and it have various features.The capacity of it ranges from 1kg to 5 kg.This is a scaled down model of a large production machine where sample package is dyed to develop recipe to achieve certain shade which can then be transferred to production machine.
Hydraulic Press
To press down loose stock and helenca muffs into packing cylinder with suitable adopters and movable turntable trolley.